Metal cutting : research advances / J. Paulo Davim, editor.

Format:

Book

Contributor:

Davim, J. Paulo.

Series:

Materials and manufacturing technology series.

Material and manufacturing technology

Language:

English

Subjects (All):

Machining.

Metal-cutting.

Physical Description:

1 online resource (257 p.)

Edition:

1st ed.

Place of Publication:

New York : Nova Science Publishers, c2010.

Language Note:

English

Summary:

Metal cutting is technology with great interest for several important industries such as automotive, aeronautics, aerospace, alternative energy, moulds and dies, biomedical, etc. This book offers a review of the latest research.

Contents:

Intro

METAL CUTTING: RESEARCH ADVANCES

CONTENTS

PREFACE

Chapter 1 METAL CUTTING: SYSTEM OUTLOOK OF RESEARCH AND APPLICATION ASPECTS

ABSTRACT

1. INTRODUCTION

2. THE IMPORTANCE OF MACHINING SYSTEM COHERENCE IN RESEARCH AND APPLICATION PRACTICES

3. DEALING WITH SYSTEM ISSUES

3.1. Chip Compression Ratio

3.1.1. Definition

3.1.2. Significance

3.2. Péclet number

3.2.1. Definition

3.2.2. Practical Use in Modeling

3.2.3. Practical Use in Testing

3.3 Poletica number

3.3.1 Definition

3.3.2. Practical Use in Modeling and Testing

3.4. Some Other Similarity Numbers: A, Silin, D, E Criterion

3.5. Machinability Studies Using Similarity Numbers

REFERENCES

Chapter 2 PREDICTION OF HEAT PARTITION IN METAL CUTTING − A STATE-OF-THE-ART REVIEW OF CONVENTIONAL TO HIGH-SPEED MACHINING

NOMENCLATURE

Greek Symbols

Subscripts

2. HIGH-SPEED MACHINING (HSM)

3. TRIBOLOGICAL TOOL COATINGS

4. HEAT GENERATION IN METAL CUTTING PROCESS

4.1. Evaluation of Heat Generation in Metal Cutting Processes

4.2. Estimation of Non-Uniform Heat Flux Along the Tool-Chip Interface

5. A REVIEW OF PREVIOUSLY REPORTED VALUES OF HEAT PARTITION BETWEEN THE TOOL AND THE CHIP

6. EXISTING ANALYTICAL MODELS FOR THE PREDICTION OF HEAT PARTITION

6.1. Loewen and Shaw Heat Partition Model

6.2. Reznikov Heat Partition Model

6.3. Gecim and Winer Heat Partition Model

6.4. Shaw Heat Partition Model

6.5. Berliner and Krainov Heat Partition Model

6.6. Tian and Kennedy Heat Partition Model

6.7. Kato and Fujii Heat Partition Model

7. SOME COMMENTS ON THE EXISTING HEAT PARTITION MODELS AND THEIR LIMITATIONS

8. FINITE ELEMENT MODELLING

8.1. Thermal Properties of the Workpiece, and Uncoated and Coated Tool Materials.

9. EXPERIMENTAL TESTS

9.1. Experimental Set-Up

9.1.1. Machining Conditions

9.1.2. Cutting Tool Materials

9.1.3. Workpiece Material

9.2. Temperature Measurements

10. RESULTS AND DISCUSSIONS

10.1. Cutting Forces

10.2. Tool-Chip Contact Area

10.3. Tool-Chip Contact Phenomena

10.3.1. Determination of Sticking and Sliding Zones for Uncoated, and TiN- and TiAlN-Coated Tools

10.4. Heat Partition into the Cutting Tool

10.4.1. For Uncoated Carbide Cutting Tool

10.4.2. For TiN-Coated Tool

10.4.3. For TiAlN-Coated Tool

11. CONCLUSION

Chapter 3 MECHANICAL AND THERMAL EXPERIMENTS IN CUTTING PROCESS FOR NEW BEHAVIOUR LAW

Evolution and Revolution in the Scientific Approach to the Cutting Process

2. MOMENTS AT THE TIP OF THE TOOL

2.1. Experimental Devices

2.2. Examples of Experimental Mechanical Results

2.2.1. Turning Mechanical Results

2.2.2. Milling Mechanical Results

2.3. Analysis of the Mechanical Experimental Results

2.3.1. First Part - Energy Considerations

2.3.2. Second Part - Mechanical Considerations

2.4. Conclusion

3. TEMPERATURE MEASUREMENT DEVICE AT THE TIP OF THE TOOL

3.1. Examples of Experimental Results

3.1.1. Thermal Measurement Results in Turning

4. MECHANICAL / THERMAL ENERGY BALANCE

5. EXPERIMENTAL CONCLUSIONS

6. A THREE-DIMENSIONAL SEMI-ANALYTICAL THERMO MECHANICAL CUTTING MODEL

6.1. Model Description

6.2. Thermomechanical Model of the Cutting Process

6.2.1. Thermal Transfers in Cutting Zones

6.2.2. Behaviour Laws in the Shear Zones

6.2.3. Thermal Balance Sheet

6.2.4. Analysis

7. ANALYSIS AND DISCUSSION ON THE VALIDITY OF THE BEHAVIOUR LAWS USED CLASSICALLY IN CUTTING MODELS

7.1. Reproduction of Complex Contact Tool-Chip Phenomena

7.1.1. Experimental Device.

7.1.2. Results of the Friction Forces

7.1.3. Results of the Friction Moments

7.2. Second Gradient Theory - New Behaviour Law Forms for the Secondary Shear Zone

8. CONCLUSION

ACKNOWLEDGMENTS

Chapter 4 FINITE ELEMENT MODELLING OF MACHINING ALUMINIUM ALLOY (AL 7075) AND EXPERIMENTAL VALIDATION

2. FEM ANALYSIS

3. METHODOLOGY

Experimental Procedure

FEM Machining Input Parameters

Experimental Validation

4. RESULTS AND DISCUSSION

FEM Analysis Validation with Coulomb Friction Coefficient

FEM Analysis Validation with Coefficient Friction Adjustment

Modelling and Prediction

Cutting and Feed Forces, Cutting Power, and Maximum Cutting Temperature

Plastic Strain, Plastic Strain Rate, and Maximum Shear Stress

5. CONCLUSIONS

ACKNOWLEDGMENT

Chapter 5 DIAMOND-COATED CUTTING TOOLS FOR MACHINING APPLICATIONS

2. DIAMOND-COATED TOOLS - STATE OF THE KNOWLEDGE

2.1. Substrate Materials and Geometry

2.2. Substrate Surface Treatments

2.1.3. CVD Processes

2.4. Coating Characterizations

2.5. Machining Performance

3. RECENT DEVELOPMENTS

3.1. Diamond Deposition

3.2. Coating Characterizations

3.3. Machining Performance

3.3.1. NCD vs. MCD and PCD Tools

3.3.2. Machining Parameter Effects

3.3.3. Cutting Edge Radius Effects

3.3.4. Coating Thickness Effects

3.4. Tool Condition Monitoring

3.5. Deposition Residual Stress Simulations

3.5.1. Cutting Edge Radius Effects

3.5.2. Coating Thickness Effects

3.5.2. Diamond Coated Twist Drills

4. CONCLUSION

Chapter 6 GENERATION AND MODELLING OF SURFACE ROUGHNESS IN MACHINING USING GEOMETRICALLY DEFINED CUTTING TOOLS

1. INTRODUCTION.

2. SURVEY OF SURFACE ROUGHNESS MODELS

2.1. Geometrical/Kinematical Models

2.2. Models Considering Minimum Undeformed Chip Thickness

2.3. Models Considering Real Tool Rake Configurations

2.3. Models Considering Material Side Flow Effect

2.4. Models Considering Quality/Preparation of the Cutting Edge=

2.5. Models Considering Deterioration/Relative Displacement of Tool Nose Traces

2.5.1. Fundamentals of Profile Decomposition Method

2.5.2. Machining Tests and Measurements of Surface Roughness

2.5.3. Coefficient of Profile Deformations Versus Process Variables

2.5.4. Predictions of Profile Deformations and Surface Roughness Parameters

2.5.5. Wavelet Image of Surface Profile Distortions

3. SUMMARY

Chapter 7 CHATTER MODELING IN DRILLING AND MICRODRILLING

2. INVESTIGATION OF CHATTER IN DRILLING

2.1. Torsional-Axial Model

2.2. Bending Model

2.3. Combination of the Bending and Torsional-Axial Models

2.4. Chatter Suppression

3. INVESTIGATION OF CHATTER IN MICRO DRILLING

4. CONCLUSIONS

Chapter 8 ASSISTED MACHINING PROCESSES

2. HIGH-PRESSURE ASSISTED PROCESSES

2.1. Test Results in Turning of Titanium Alloys

2.2. High-Pressure Assisted Milling

2.3. High-Pressure Assisted Drilling

2.3.1. Test Results in Titanium Alloys

2.3.2. Test Results in Stainless Steels

3. COLD AND CRYOGENIC MACHINING

3.1. Cold Air

3.2. CO2 Assisted Machining

3.3. Liquid Nitrogen as Coolant

4. VIBRATION-ASSISTED MACHINING

4.1. Modulation-Assisted Machining

4.2. Ultrasonic Assisted Machining

4.2.1. Ultrasonic-Assisted Turning

4.2.2. Ultrasonic-Assisted Drilling

4.2.3. Ultrasonic Elliptical Cutting

5. THERMAL-ENHANCED MACHINING

5.1. Laser-Assisted Machining.

5.2. Plasma-Assisted Processes

5.2.1. Plasma-Assisted Milling Results in Nickel Alloys

6. CONCLUSIONS

INDEX

Blank Page.

Notes:

Description based upon print version of record.

Includes bibliographical references and index.

Description based on print version record.

ISBN:

1-61122-573-6

OCLC:

670429758